Automatic multiple wire wrapping machine



Jan. 10, 1967 L. J. TRQTTA 3,297,059

AUTOMATIC MULTIPLE WIRE WRAPPING MACHINE Filed Sept. 24, 1964 6Sheets-Sheet l 3 FIG-.1 3

INVENTOR LEONARD J. TROTTA ATTORNEY Jan. 10, 1967 L. J. TROTTA 3,297,059

AUTOMATIC MULTIPLE WIRE WRAPPING MACHINE Filed Sept. 24, 1964 6Sheets-$heet 2 lNl/ENTOR LEONARD J. TRO'TTA A T TORNEY Jan. 10, 1967 L.J. TROTTA AUTOMATIC MULTIPLE WIRE WRAPPING MACHINE 6 Sheets-Sheet 3Filed Sept. 24, 1964 FIG 3 FIG. IO

//VVENTOR LEONARD J TROTTA A TTORNEY Jan. 10, 1967 L. J. TROTTA3,297,059

AUTOMATIC MULTIPLE WIRE WRAPPING MACHINE Filed Sept. 24, 1964 6Sheets-Sheet FIG.4 53 56 F'IG.5

INVENTOR LEONARD J. TRO'TTA ATTORNEY Jan. 10, 1967 L. J. TROTTA3,297,059

AUTOMATIC MULTIPLE WIRE WRAPPING MACHINE Filed Sept. 24, 1964 eSheets-Sheet s FIG.6

I05 7 LEONARD J. TROTTA A T TORNEV K INVENTOR Jan. 10, 1967 J. TROTTAAUTOMATIC MULTIPLE WIRE WRAPPING MACHINE 6 Sheets-Sheet (5 Filed Sept.24, 1964 ATTORNEY United States Patent 3,297,059 AUTOMATIC MULTIPLE WIREWRAPPING MACHINE Leonard J. Trotta, 17811 Locherbie, Southiield, Mich.48075 Filed Sept. 24, 1964, Ser. No. 399,005 8 Claims. (Cl. 140-45) Thisinvention relates to improvements in automatic wire wrapping machineryand in particular to a machine for winding or wrapping a plurality ofwires around another wire or wires.

The machine of the invention is especially useful and eflicient in themanufacture of coil spring units used in bed springs, mattresses, seats,seatbacks, sofas, davenports, cushions, and the like. A coil spring unitof this type has rows of coil springs which may be connected at one endof the coil by bottom cross-support wires interwound in the base of thecoil of each spring, by a wooden frame connected to the base of the coilsprings, by metal frame members, or by other means as desired.

The tops of the coil springs are relatively movable and constitute therelatively resiliently movable portion of the spring unit to provideflexibility. A relatively heavy continuous peripheral wire or base wiresurrounds the assembly of coil springs at theirtop. Top cross-tie wiresare woven through the top spiral of each coil spring. The cross-tiewires are in two sets usually with each set lying normal to the other.The cross-tie wires thereby hold the top spiral of each coil spring inposition in the unit and together with the top spiral of the coilsprings form a mesh for supporting upholstery .padding. The ends of thecross-tie wires extend past the peripheral edge wire prior to bending orwrapping. The extending ends of the cross-tie wires are then bent in aloop or wrapped around the peripheral edge wire.

In the prior art the cross-tie wires are usually bent into a U-shapearound the peripheral edge wire by hand using a hand tool. Sometimes afew cross-tie wires are wound around the peripheral edge wire by hand orby use of a power tool. It is preferable that all the one or two wiresor may be modified to wrap more than three wires at one time, Also thespring unit may have the same construction at both top and bottom, suchas in a da venport cushion and the wires also wrapped at the bottom ofthe unit.

With the foregoing in view, it is a primary object of the invention toprovide an automatic multiple wire wrapping or winding machine which issimple in design and construction, positive and efficient in action,inexpensive to manufacture, which is capable of high-speed productionuse, which is durable in operation over a long period of time to obviatebreakdown and interruption of its high production capacity, and which iseasy and facile to use.

An object of the invention is to provide a machine for wrapping wiresaround a base wire or wires which has a mouth or receiver portion whichproperly positions the wires relative to each other and relative to themachine.

An object of the invention is to provide a machine having abutments orbosses which position and secure the wires while they are being wrappedor wound.

top cross-tie wires be wound around the peripheral edge 1 or base wireas this makes the spring unit stronger by eliminating end-play in thecross-tie wires and by securely connecting the peripheral edge or basewire with the other components in the spring unit.

A first set of three cross-tie wires may be inter-connected through thetop spiral of each coil spring in one direction and a second set of topcross-tie wires inter-connected through the top spiral of each coilspring with a second set lying normal to the first set. The op positeends of both sets of wires extend beyond the peripheral edge wire at thesides and ends of the spring An object of the invention is to provide amachine having wire positioning and holding gates which maintainengagement of the wire with the wrapping element or dogs of the machine.

An object of the invention is to provide an automatic system for themachine controlling its operation.

An object of the invention is to provide power means and adjustableoperating means in the machine which are simple and effective to wrapthe wires the desired number of turns and to leave the ends of thewrapped wires extending inwardly of the spring unit. 7

These and other objects of the invention will become apparent byreference to the following description of the automatic wire wrappingmachine embodying the invention taken in connection with theaccompanying drawings in which:

FIG. 1 is a face elevational view of a machine embodying the inventionwith the main power cylinder and supporting base broken away.

FIG. 2 is an enlarged cross-sectional view of the machine of FIG. 1fore-shortened in the .piston rod location taken on the line 22 of FIG.1 showing the power cylinder, rack, pinion gear, a wire wrapping gear,and other structural elements, and showing the spring unit in dottedlines.

FIG. 3 is an enlarged top plan view of the machine of FIG. 1 taken onthe line 3-3 thereof showing the positioning and holding gates, thecylinder for actuating the gates, the wire positioning troughs, andother structural elements.

unit and must be bent back or preferably wound around the peripheraledge wire. The center Wire of each set is also wound around the topspiral of the coil spring at its tangent point to the peripheral edgewire. This not only connects the cross-tie wires and peripheral edgewire together, but also connects the top spirals of the outer coilsprings to the peripheral edge wire.

The machine of the invention has been developed to securely wind thecenter cross-tie wire of each set around the peripheral wire and the topspiral of the coil spring at which the peripheral edge wire lies tangentand at the same time to wrap the side cross-tie wires of each set aroundthe peripheral edge wire in one operation. This occurs automaticallyupon the operator positioning the unit and wires in the machine andinitiating its operation. The machine then securely wraps or winds thecross-tie wires as stated.

While a set of three cross-tie wires is shown and described as anexample, the machine may be used to wrap FIG. 4 is an oblique partialcross-sectional view of FIG. 2 taken on the line 4-4 thereof showing therack, pinion gear, the wrapping gears, and other structural elements.

FIG. 5 is a partial crosssectional view of the top portion of themachine as seen in FIG. 2 with the rack in the down position after theWires are wrapped cocking the clamping guide open to permit easy removalof the spring unit and showing a spring unit in dotted lines.

FIG. 6 is a cross-sectional view of FIG. 2 taken on the line 6-6 thereofshowing the wrapping gears and side gates and with the spring unit indotted lines prior to the wrapping operation.

FIG. 7 is a schematic partial cross-sectional view of FIG. 8 taken onthe line 7-7 thereof showing the gate structure and showing linkage andthe spring unit in dotted lines. FIG. 8 is a partial cross-sectionalview of the machine such as on the line 8--8 of FIG. 7 showing awrapping gear, trough, positioning means, and stop means and showing thewires of a spring unit in dotted lines.

FIG. 9 is a partial cross-sectional view of the machine such as on theline 99 of FIG. 8 showing a gate and linkage in the operated or closedposition.

FIG. 10 is a perspective fragmentary view of the top spiral of a coilspring, a peripheral wire, a first set of three cross-tie wires, and asingle center transverse crosswire lying normal to and interlaced withthe wires of the first set prior to the wrapping operation.

FIG. 11 is a top plan view of the device of FIG. 10

after the wrapping operation; and

FIG. 12 is a diagrammatic showing of the machine automatic power andcontrol system and components.

Referring now to the drawings wherein like numerals refer to like andcorresponding parts throughout the several views, the automatic wirewrapping machine disclosed therein as an exemplary embodiment of theinvention comprises a machine frame mounted on a support 21 whichpositions the machine at the desired height, FIG. 2. The machine 20 hasa base 22 to which a rack actuating cylinder 23 is attached by aplurality of bolts 24 and nuts 25. The cylinder 23 has a piston rod 26leading through the base 22. The rack 27 is connected on the piston rod26 by a collar 28. The collar 28 has adjustably extendable set screws 29abutting stops 30 on the machine frame 20. The adjustment of the setscrews 29 and stops 30 properly locates the rack 27 in position relativeto the gears rotated by the rack 27 as hereinafter set forth.

The rack 27 has a back web 31, FIGS. 2 and 3. A pair of bearings 32 and33 abut the back of the rack 27 on the opposite sides of the web 31. Thebearings 32 and 33 permit up and down movement of the rack 27 andsupport and position the rack linearly in its movement. The bearings 32and 33 are in turn supported on a shaft 34 con nected to the machineframe 20.

An intermediate drive pinion gear 35, FIGS. 2, 4, and 5, meshes with therack 27. The pinion gear 35 is fixed on a drive shaft 36 which isrotatably supported by the machine frame 20. Three drive gears 37, 38and 39 are also fixed on the drive shaft 36 and rotate therewith.

A center wire wrapping gear 40 meshes with the drive gear 38. Side wirewrapping gears 41 and 42 mesh with the drive gears 37 and 39respectively on either side of the center wire wrapping gear 46. Thewire wrapping gears 40, 41, 42 are rotatably supported externally ratherthan internally. The wrapping gears 40, 41 and 42 have hollow hubs 43,44, and 45 respectively. A plate 46 abuts one side of the wrapping gear40 and has an aperture receiving and surrounding the hub 43. A flangedcollar 47 abuts the other side of the wrapping gear 40. A plate 48 abutsthe collar 47. A plug 49 having a frustoconical outer surface abuts theplate 48, collar 47, and the hub 43. The hub 43 has a frusto-conicalinternal surface mating the plug 49. All the parts are radiallyinterrupted forming a slot 50 radially of the hub 43 defining areceiving mouth. The slot 50 allows the insertion of the spring unitperipheral edge base wire and a tangential portion of an adjacent topspiral of a coil spring unit so that they lie axially within the hub 43and wrapping gear 411.

In this connection it will be understood that the wrapping gear 40 andhub 43 are interrupted radially by the slot 51). The internal axialportion of the hub 43 lies at the tangent point of the top spiral coilof the spring unit at the peripheral edge wire and the arcuate portionof the adjacent coil of the spring lies within the internal conicalportion of the hub 43. The internal conical portion of the hub 43permits it to by-pass the arcuate portion of the top spiral of the coiladjacent the tangent point of the peripheral edge wire. Only thewrapping gear 40 and hub 43 rotate; the other parts remain stationary.The hub 43 carries a boss 51 which engages the cross-tie wire to bewrapped and winds the cross-tie wire around the peripheral edge wire andthe top spiral of the spring coil as it rotates with the wrapping gear40 and hub 43 as hereinafter more fully described in conjunction withthe operation of the machine. The stationary plug 49 holds the topspiral of the coil in position during the wrapping operation by abuttingthe adjacent arcuate portion of the spiral of the spring coil.

The side wrapping gear 41 and hub 44 are axially and radially rotatablypositioned by the side plates 52 and 53. The plate 52 is relieved in thelocation of the gears 41 and 37. The plates 52 and 53 have aperturesreceiving the hub 44 on either side of the gear 41. The plates 52 and53, gear 41, and hub 44 are interrupted by a radial slot 50A whichallows the peripheral edge wire to be located on the axis of the gear 41and hub 44. The hub 44 is equipped with a boss 54 which engages thecross-tie wires to be wrapped and winds the cross-tie Wire around theperipheral edge wire as the boss 54 rotates with the wrapping gear 41and hub 44-.

Likewise the side wrapping gear 42 and hub 45 are axially and radiallyrotatably positioned by a side plate 55 and a side plate 56. The plate55 is relieved in the location of the gear 42 and hub 39. The plates 55and 56 have apertures receiving the hub 45 on either side of the gear42. The plates 55 and 56, gear 42, and hub 45 are interrupted by aradial slot 50B which allows the peripheral edge wire to be located onthe axis of the gear 42 and hub 45. The hub 45 is equipped with a boss57 which engages the cross-tie wire and winds it around the peripheraledge wire as the boss 57 rotates with the wrapping gear 42 and hub 45.

The length of the rack 27 and the size of the pinion gear 35 as well asthe size of the intermediate drive gears 37, 38, and 39 and the size ofthe wire wrapping gears 40, 41, and 44 are designed so that the wirewrapping gears 40, 41 and 44 make the desired number of revolutions whenthe rack is moved.

A nose plate 58 is mounted on the machine 20, FIGS. 1, 2, 3, 5, and 6.The nose plate has three guide troughs 59, 60, and 61. Each trough has awide front narrowing inwardly and upwardly constituting receivingportion 62 leading and converging to a locating channel portion 63. Thechannel portion 63 of each trough 59, 60, and 61 is positioned so as toprovide a Wire guide leading in projected extension closely above thebosses 54, 51, and 57 closely to the sides of the hubs 44, 43, and 45respectively. The troughs 59, 60, and 61 properly locate the extendingends of the cross-tie wires above the bosses 54, 51 and 57 in thedesired location when the wires are inserted in the machine.

A stop abutment 64 and a stop abutment 65, FIGS. 3, 6, and 8 ispositioned inwardly of the nose plate 58 inwardly of the side troughs 59and 61 respectively. The stops 64 and 65 engage a crimp in the sidecross-tie wires. The abutment of the crimp in the wire against the stopprevents pulling the wire inwardly during the winding operation.

A side gate 66, FIGS. 3, 6, and 7, is pivotally hinged on a pin 67carried by an arm 68 on the machine frame 20. The side gate 66 closessidewise against the side of a cross-tie wire in the trough 59 to holdcross-tie wires in the desired vertical plane above the boss 54 on thehub 44 of the side wrapping gear 41.

A side gate 69 is pivotally hinged on a pin 71) carried by an arm 71 onthe machine frame 20. The side gate 69 closes sidewise against the sideof a cross-tie wire in the trough 60 holding it in the desired verticalplane above the boss 51 on the hub 43 of the center wrapping gear 40.

A side gate 72 is pivotally hinged on a pin 73 carried by an arm 74 onthe machine frame 20. The side gate 72 closes sidewise against the sideof a cross-tie wire in the trough 61 holding it in the desired verticalplane above the boss 57 on the hub 45 of the side wrapping gear 42.

The gates 66, 69, and 72 are actuated by linkage which comprises a powercylinder 75 mounted on the machine frame 20. The cylinder has a pistonrod 76 equipped With a clevis 77. The clevis 77 has a pin 78 engaging anend of a bell-crank 79. The bell-crank 79 is fulcrummed on the gate 69on the stud 80. The other end of the bellcrank 79 is pivotally connectedby a pin 81 to a link 82. The link 82 is pivotally mounted on the gate66 by a stud 83. A second link 84 has an end pivotally mounted on thestud 80 on the gate 69. The other end of the link 84 is connected to thegate 72 by a stud 85. The linkage and gates are shown in the closedposition in FIGS. 3 and 6 and in the open position in FIG. 7. The clevis77 has an extension 86 which abuts a poppet valve 87 which actuates therack cylinder 23.

In the open position of the gates 66, 69, and 72, FIG. 7, the gatepiston rod 76 is extended from the cylinder 75. In the closed positionof the gates 66, 69, and 72, the piston rod 76 is retracted into thecylinder '75, FIGS. 3 and 6.

A top clamping guide 88, FIGS. 2 and 5, is pivoted on the machine frame20 on a pin 89. A spring 90 is fixed on the machine frame 20 and bearsagainst the clamping guide 88 urging it downwardly into clampingposition. The inner end of the clamping guide 88 has a depending portion91 equipped with a cam surface 92. The cam surface engages an arm 93 onthe rack 27, FIG. 5, in the down position of the rack 27. The arm 93 onthe rack 27 cams against the cam surface 92 on the extension 91 movingit inwardly which moves the clamping guide 88 upwardly against thespring 90. This opens the clamping guide 88 automatically when the rack27 reaches its down position. When the rack moves upwardly, its initialmovement releases the clamping guide 88, permitting it to close underthe power of the spring 90. When the rack 27 is in its final downwardmovement, the clamping guide depending portion 91 is engaged by the arm93 and the guide 88 is opened against the power of the spring 90.

A fluid pressure system, FIG. 12, powers and operates the automaticcycle of the machine and air pressure is described as an example. Airpressure supply line 106 supplies air to a two-position control valve107 through a line 108. The supply line 106 also furnishes air to a twoposition control valve 109 through a line 110. The control valves 107and 109 are mounted on the machine support 21. Each control valve has aslide piston controlling the air distribution and feed of the valve. Thedistribution piston of each valve moves from one end of the valve to theother upon venting an orifice controlled by a first poppet valve. Thedistribution piston stays at that end until another orifice is vented bya second poppet valve and then it moves back to its first position. Thisis well understood by those having ordinary skill in the fluid valve artand such devices are readily available on the market.

The poppet valve 87 is connected by a line 111 to one end of the controlvalve 109. A poppet valve 112 is connected by a line 113 to the otherend of the rack control valve 109. The rack control valve 109 isconnected by lines 114 and 115 to the opposite ends of the rack cylinder23. Actuation of the poppet valve 87 actuates the rack control valve 109to feed air via the line 115 to the rack cylinder 23 to move the rack 27upwardly. Actuation of the poppet valve 112 actuates the rack controlvalve 109 to feed air to the rack cylinder 23 to move the rack 27downwardly.

The poppet valve 94 is connected by a line 116 to one end of the gatecontrol valve 107. A poppet valve 117 is connected by a line 118 to theother end of the gate control valve 107. The gate control valve 107 isconnected by lines 119 and 120 to the opposite ends of the gate cylinder.75. Actuation of the poppet valve 94 actuates the gate control valve107 to feed air via the line 119 to the gate cylinder 75 to open thegates and to move the clevis extension 86 outwardly. Actuation of thepoppet valve 117 actuates the gate control valve 107 to feed air via theline 120 to close the gates and to move the clevis extension 86inwardly.

A foot pedal 121 is pivoted on a base 122 as at 123.

6 A spring 124 normally locates the pedal 121 in the up position shown.The pedal 121 has a cam face 125 which contacts the popped valves 112and 117. The pedal is moved downwardly manually and moved upwardly bythe spring 124.

A poppet valve 126 is connected in parallel with the poppet valve 94.This is a hand operated poppet valve separate from the automatic cycleof the machine. The. poppet valve 126 is provided to allow the operatorto reverse the cycle should a jam occur or should the rack collar 28fail to actuate the poppet valve 94.

The normal condition of the pneumatic system is illustrated in FIG. 12with the rack cylinder 23 positioning the rack 27 upwardly and the gatecylinder 75 holding the gates open with the clevis extension 86positioned outwardly. This condition is established by actuation of thepoppet valve 112. When the operator lifts his foot from the pedal 121,the spring elevates the cam face 125 off the poppet valve 117 intocontact with the poppet valve 112.

Upon actuation of the poppet valve 112, air is released from the line113 causing the rack control valve 109 to take a position venting airfrom line 114 and feeding air to line moving the rack 27 to the upposition. When the operator again depresses the pedal 121, the cam face125 first moves past and actuates the poppet valve 112. This does notcause a change in the system because the system has already responded topoppet valve 112 actuation.

As the operator fully depresses the pedal 121, the cam face 125 contactsand actuates the poppet valve 117. This causes the gate control valve107 to shift venting air from line 119 and feeding air to line 120. Thiscauses the gate piston rod, clevis, and clevis extension 86 to moveinwardly relative to the cylinder 75. This closes the gates. This alsobrings the clevis extension 86 into contact with poppet valve 87.

Upon the actuation of the poppet valve 87, the rack control valve 109shifts position venting air from line 115 and feeding air to line 114causing the rack piston rod, rack 27, and collar 28 to move downwardly.This brings the rack collar 28 into contact with the poppet valve 94which actuates gate control cylinder 107 to shift position venting airfrom line and feeding air to line 119 causing the gate piston rod, andclevis to extend opening the gates and moving the clevis extension ohthe poppet valve 87.

Thus upon the operator depressing the foot pedal the gates areautomatically closed. Thus upon the gates being closed, the rack isautomatically moved down and the wire wrapping operation performed. Thusupon the operator lifting his foot from the pedal, the rack isautomatically moved up to receive the next wires to be wrapped.

Preparatory to operation of the machine, the operator opens a valve tothe main air supply line 106. This furnishes an ever ready supply of airto the control valves 107 and 109 which, in turn, supply the cylindersand systerm with air. In the normal or ready condition of the system thefoot pedal 121 is up, the gates are open, and the rack is up.

The foot-operated two position pedal 121 controls the operation of themachine leaving the operators hands free. When the operator depressesthe pedal 121, the gate power cylinder moves first to close the gatesagainst the Wires to be wound. Upon the gates closing, the clevisextension 86, contacts the poppet valve 87 which causes the rack to movedownwardly to wind or wrap the wires.

The rack 27 moves downwardly until the collar 28 depresses the poppetvalve 94 opening the gates. The operator then removes the wrapped wireassembly, then the operator releases the foot pedal 121, and the springmoves the pedal cam face past poppet valve 112 which causes the systemto move the rack upwardly to the ready position.

FIGS. 10 and 11 show a portion of a spring unit having a relativelyheavy peripheral edge base wire 100, a top spiral 101 of a coil spring,a center cross-tie wire 102, side cross-tie wires 103 and 104, and aninterlaced transverse cross-tie wire 105 lying normal to the cross-tiewires 102, 103, and 104.

In operation of the machine 20, the operator opens the valve to the mainsupply line 106 in the pneumatic system. This furnishes air pressuresupply to the rack cylinder 23 an dthe gate cylinder 75 as controlled bythe control valves and actuating poppet valves in the system. In theready condition of the system, the foot pedal 121 is in the up orelevated position. This position last actuates the valve and controlmeans furnishing air power to the proper side of the rack power cylinder27 to move it to the up position as illustrated in FIGS. 1 and 2 and tomove the gate cylinder 75 to the extended position, FIG. 7, opening thegates 66, 69, and 72. The set screws 29 are adjusted relative to thestops 30 on the machine 20 so that the rack in its up position hasrotated the wire winding gears 40, 41, and 42 so that their respectiveslots 50, 50A, and 50B open outwardly towards the delivery portion ofthe troughs 60, 59, and 61 respectively in parallel with the slots ofthe support plates defining the mouth of the machine.

The operator then takes a spring assembly having sections such as seenin FIG. 10, and moves the extending ends 102A, 103A, and 104 of thecross-tie wires into the troughs 60, 59, and 61 respectively until theprojecting ends of the cross-tie wires have passed the dogs 51, 54, and57 on the wire winding gears 40, 41, and 42 respectively and until theperipheral edge base wire 100 abuts the internal periphery of theannular wall in the hubs 43, 44, and 45 defining the interior end of theslots 50, 50A, and 50B. This condition is illustrated in FIG. 6. Ininserting the wire assembly of FIG. 10 as hereinbefore described intothe mouth of the machine, the peripheral edge wire 100 and the topspiral 101 of the coil spring are forced past the clamping guide 88against the spring 90. In this regard the guide 83 elevates against thespring 90 to permit the passing of the wire assembly and then is springpressed into clamping position to hold the wire assembly in the insertedposition. The machine is now ready to wrap the extending ends 102A,103A, and 104 of the cross-tie wires.

The operator then depresses the foot pedal actuating the poppet valve117 causing the control valve to supply air to the gate cylinder toclose the gate. The gate cylinder 75 retracts the piston rod 76actuating the gate closing linkage to close the gates which forces theextending wire ends 102A, 103A, and 104 into a vertical plane over thedogs 51, 54, and 57 on the hubs 43, 44, and 45 of their respectivewrapping gears.

Upon the gates being closed, the extension 86 on the clevis 77 closesthe poppet valve 87 which actuates the rack control valve 109 to supplyair to the rack cylinder 23 to retract the piston rod 26 moving the rack27 downwardly. As the rack 27 moves downwardly it rotates theintermediate drive pinion gear 35 and the drive shaft 36 upon which thefinal drive gears 37, 38, and 39 are also fixed. The rotation of thefinal drive gears 37, 38, and 39 causes the rotation of the wirewrapping gears 41, 40, and 42 respectively together with their hubs 44,43, and 45 respectively. This causes the dogs 54, 51, and 57 on theirrespective hubs 44, 43, and 45 to rotate and respectively contact theprojecting ends 103A, 102A, and 104 of the cross-tie wires. In theirrotation, the dogs 54, 51, and 57 orbit around the peripheral edge wire100 and wrap the extending ends of the cross-tie wires 103A, 102A, and104 around the preipheral edge wire 100. In this regard the dogs 54, 51,and 57 make several revolutions in their orbiting of the peripheral edgewire 100 and wrap the extending ends 103A, 102A, and 104 several timesaround the peripheral edge wire 100 as seen in FIG. 11.

Immediately after the wire wrapping operation is completed, the collar28 on the rack piston rod 26 contacts the poppet valve 94 actuating thegate control valve 107 to supply air to the gate power cylinder 75 toextend the piston rod 76 to actuate the linkage to open the gates 66,69, and 72. This frees the wrapped wire assembly relative to the gates.Also upon the rack 27 reaching its down position, FIG. 5, the arm 93 onthe rack 27 contacts the cam surface 92 of the extension 91 on theclamping guide 86 moving the clamping guide 88 upwardly against thespring 90 and freeing the wrapped wire assembly relative to the clampingguide 88.

The operator then removes the wrapped portion of the wire assembly asseen in FIG. 11 from the machine.

The operator removes his foot from the operating pedal permitting thepedal to move to its spring biased upposition which actuates the poppetvalve 112 which causes the rack power cylinder to move the rack 27 tothe up position as seen in FIG. 1. The device is now ready to haveanother portion of the wire unit assembly as seen in FIG. 10 insertedand wrapped as previously described.

From the foregoing it will be understood that the operator simply turnson the main air supply valve and this simple operation places themachine automatically in the ready position. He then inserts the wireunit assembly as seen in FIG. 10 in the machine and depresses the footpedal. The machine then automatically clamps and wraps the cross-tiewires around the peripheral edge wire and unclamps the wires. He thenextracts the wrapped section of the wire unit from the machine andreleases his foot from the pedal and the machine automatically moves tothe ready position to receive the next unwrapped portion of the wireunit.

The machine provides guide troughs to properly locate the projectingends of the cross-tie wires in the machine in a horizontal plane,automatic gates to properly locate the cross-tie-wires in a verticalplane relative to the wrapping dogs, and the clamping guide to hold theassembly in the machine when fully inserted.

The machine also furnishes automatic releasing mechanism to free thewraped wire assembly upon the crosstie wires being wrapped on theperipheral edge Wire. This is effected by the gates automaticallyopening upon the wires being wrapped and upon the clamping guide 88being moved allowing the operator to extract the wrapped wire portion ofthe assembly from the machine.

The machine provides automatic means for wrapping three cross-tie wiresautomatically as illustrated and described. However, it is within theperview of the invention to wrap any number of wires as may be desiredand suitable in the production of the spring unit to suit the bestefiiciency of the operation. While the machine has been shown anddescribed as pneumatically controlled and operated, it is believed thatequivalent hydraulic, mechanical, and electrical systems are within thescope of the invention.

Although but a single pneumatic embodiment of the inventive machine hasbeen disclosed and described in detail, it is obvious that many changesmay be made in the size, shape, detail, and arrangement of the variouselements in the invention within the scope of the appended claims.

I claim:

1. An automatic wire wrapping machine for winding a plurality of wiresaround a base wire at the same time comprising,

a plurality of wire wrapping gears on a common rotational axis, eachsaid gear having opposite sides, a hub projecting axially on either sideof each said wire wrapping gear, a circumferential edge, and a radialslot leading through said circumferential edge and said hub to a pointbeyond and including the rotational axis of said wire wrapping gear;

a machine frame,

paired mounting plates on said machine frame on either side of each saidwire wrapping gear; said plates hav- 9 ing aligned bearing aperturesreceiving and rotatably mounting each said hub and abutting the oppositesides of each said wire wrapping gear;

each said mounting plate having a receiving slot leading to its saidbearing aperture and aligned parallel relative to one another defining awire receiving mouth in the machine leading to the radial slot in eachsaid wire Wrapping gear;

said wire wrapping gears being rotatable to align their radial slotswith the receiving slots in said plates so that a base wire movedradially sidewise through said plate slots also moves through saidradial slots of said wire wrapping gears so as to take a proper workposition with the axis of the base wire lying on the rotational axis ofsaid wire wrapping gears so that said wire wrapping gears may rotatearound said base wire;

a drive gear engaging each said wire wrapping gear,

a drive shaft rotatably mounted on said machine frame supporting saiddrive gears,

a drive pinion gear on said drive shaft,

a rack reciprocably supported on said machine frame engaging said piniongear,

a rack cylinder mounted on said machine frame having a piston rodconnected to said rack for reciprocating said rack;

movement of said rack rotating said pinion gear, drive shaft, and drivegears with said drive gears rotating said wire wrapping gears; and

a radially positioned axially projecting wire wrapping dog on each saidhub adjacent the radial slot in each said wire wrapping gear;

said rack being adjusted in reciprocating movement so that at the endsof travel in both directions said wire wrapping gears are positionedwith their radial slots in alignment with the slots in said mountingplates so that the base wire may be inserted and extracted relative tosaid wire wrapping gears;

said base wire being inserted and extracted together with cross-tiewires lying normal to the base wire with their ends projecting beyondsaid base wire and past and in the plane of said dogs on said wirewrapping gears;

rotation of said wire wrapping gears with said wires so disposedorbiting said dogs around said base wire with said dogs engaging saidcross-tie wires while orbiting, thereby wrapping the extending ends ofsaid cross-tie wires around said base wire.

2. In a machine as set forth in claim 1,

a side gate pivoted on said machine frame at each said wire wrappinggear on the side thereof having said do linkage on said frame connectedto each said gate for closing said gate against said dog to hold acrosstie wire in the plane of said dog,

and a gate operating cylinder on said frame having a piston rodconnected to said linkage for swinging and holding said gates betweenand in their open and closed positions.

3. In a machine as set forth in claim 1,

a nose plate on said frame having a receiving and channeling trough foreach said cross-tie wire funneling down to a delivery channel leading tothe mouth of said machine in the plane of each said dog on each saidwire wrapping gear facilitating quickly inserting the projecting ends ofthe cross-tie wires in the machine in the proper location and position.

4. In a machine as set forth in claim 1,

a clamping guide pivotally mounted on said frame over the mouth of saidmachine adapted to engage, channel, and locate a base wire in said wirewinding gears on their rotational axis,

a spring urging said clamping guide into clamping relationship relativeto a base wire and permitting inserltd tion of a base wire past saidclamping guide by allowing movement of said clamping guide;

said spring pressed clamping guide holding a base wire in position insaid wire wrapping gears after insertion in the mouth of the machine;

a depending portion on said clamping guide on the opposite side of saidclamping guide relative to said pivotal mounting on said frame,

and an arm on said rack adapted to engage said depending portion on saidclamping guide at the end of travel of said rack to pivot said clampingguide away from the base wire to allow easy removal of the base wirefrom the mouth of the machine.

5. In a machine as set forth in claim 1, a fluid pressure power andcontrol system including said gate cylinder and said rack cylindercomprising,

a fluid pressure supply line,

a gate control valve connected to said supply line for selectivelybi-directionally powering said gate cylinder to open said gates and toclose said gates,

a rack control valve connected to said supply line for selectivelybi-directionally powering said rack cylinder to move said rack up anddown to rotate said Wire wrapping gears;

a gate closing poppet valve and a gate opening poppet valve connected tosaid gate control valve,

a rack lowering poppet valve and a rack raising poppet valve connectedto said rack control valve;

said gate control valve and said rack control valve being actuated bytripping said poppet valves;

said gate closing poppet valve and said rack raising poppet valve beingoperationally paired;

a two position lever having a first wrap position actuating said gateclosing poppet valve and a second relocate position actuating said rackraising poppet valve;

said rack lowering poppet valve being actuated by said gate cylinderwhen said gates are closed to cause lowering said rack to orbit saidwire wrapping gears and the wires being wrapped around said base wire:

said gate opening poppet valve being actuated by said rack cylinder whenthe orbiting of said wire wrapping gears is completed;

movement of said lever to the Wrap position tripping said gate closingpoppet valve to automatically close said gates to abut the wires to bewrapped; closing said gates automatically tripping said rack loweringpoppet valve to lower said rack to orbit said wire wrapping gears towrap the wires; and completion of lowering said rack automaticallytripping said gate opening poppet valve to open said gates to releasewrapped wires for removal from the machine;

movement of said lever to the relocate position tripping said rackraising poppet valve to raise said rack to the ready position.

6. In a device as set forth in claim 5, a foot pedal constituting saidlever; said pedal having an up ready position actuating said rackraising poppet valve, and

a spring normally urging said pedal in. said up ready position;

said pedal having a down wrap position actuating said gate closingpoppet valve;

said pedal being depressable by an operator against said spring toactuate said gate closing poppet valve to set automatic cycle of saidmachine in operation;

said spring moving said pedal to the up position upon release by theoperator to actuate said rack raising poppet valve to place said rack inthe ready position.

7. An automatic Wire wrapping machine for winding 70 a plurality ofwires around a base wire at the same time comprising,

a plurality of wire wrapping gears on a common rotational axis, eachsaid gear having opposite sides, a hub projecting axially on either sideof each said wire wrapping gear, a circumferential edge, and a radialslot leading through said circumferential edge and said hub to a pointbeyond and including the rotational axis of said wire wrapping gear;

a machine frame,

paired mounting plates on said machine frame on either side of each saidwire wrapping gear; said plates having aligned bearing aperturesreceiving and rotatably mounting each said hub and abutting the oppositesides of each said wire wrapping gear;

each said mounting plate having a receiving slot leading to its saidbearing aperture and aligned parallel relative to one another defining awire receiving mouth in the machine leading to the radial slot in eachsaid wire wrapping gear;

said wire wrapping gears being rotatable to align their radial slotswith the receiving slots in said plates so that a base Wire movedradially sidewise through said plate slots also moves through saidradial slots of said wire wrapping gears so as to take a proper workposition with the axis of the base wire lying on the rotation axis ofsaid wire wrapping gears so that said wire wrapping gears may rotatearound said base wire;

a drive gear engaging each said wire wrapping gear;

a drive shaft rotatably mounted on said machine frame supporting saiddrive gears,

a drive pinion gear on said drive shaft,

a rack reciprocably supported on said machine frame engaging said piniongear,

a rack cylinder mounted on said machine frame having a piston rodconnected to said rack for reciprocating said rack;

movement of said rack rotating said pinion gear, drive shaft, and drivegears with said drive gears rotating said wire wrapping gears; and

a radially positioned axially projecting wire wrapping dog on each saidhub adjacent the radial slot in each said wire wrapping gear;

said rack being adjusted in reciprocating movement so that at the endsof travel in both directions said wire wrapping gears are positionedwith their radial slots in alignment with the slots in said mountingplates so that the base wire may be inserted and extracted relative tosaid wire wrapping gears;

said base wire being inserted and extracted together with cross-tiewires lying normal to the base wire with their ends projecting beyondsaid base Wire and past and in the plane of said dogs on said wireWrapping gears;

rotation of said wire wrapping gears With said wires so disposedorbiting said dogs around said base Wire with said dogs engaging saidcross-tie wires while orbiting thereby wrapping the extending ends ofsaid cross-tie wires around said base wire.

a side gate pivoted on said machine frame at each said wire wrappinggear on the side thereof having said dog.

linkage on said frame connected to each said gate for closing said gateagainst said dog to hold a cross-tie wire in the plane of said dog,

a gate operating cylinder on said frame having a piston rod connected tosaid linkage for swingingand holding said gates between and in theiropen and closed positions,

a fluid pressure power and control system including 12 said gatecylinder and said rack cylinder comprising,

a fluid pressure supply line,

a gate control valve connected to said supply line for selectivelybi-directionally powering said gate cylinder to open said gates and toclose said gates,

a rack control valve connected to said supply line for selectivelybi-directionally powering said rack cylinder to move said rack up anddown to rotate said Wire wrapping gears;

a gate closing poppet valve and a gate opening poppet valve connected tosaid gate control valve,

a rack lowering poppet valve and a rack raising poppet valve connectedto said rack control valve;

said gate control valve and said rack control valve being actuated bytripping said poppet valves;

first means actuating said gate closing poppet valve and second meansactuating said rack raising poppet valve;

said rack lowering poppet valve being actuated by said gate cylinderwhen said gates are closed to cause lowering said rack to orbit saidwire wrapping gears and the wires being wrapped around said base wire;

said gate opening poppet valve being actuated by said racks cylinderwhen the orbiting of said wire wrapping gears is completed;

movement of said first means tripping said gate closing poppet valve toautomatically close said gates to abut the wires to be wrapped; closingsaid gates automatically tripping said rack lowering poppet valve tolower said rack to orbit said wire wrapping gears to wrap the wires; andcompletion of lowering said rack automatically tripping said gateopening poppet valve to open said gates to release wrapped wires forremoval from the machine;

movement of said second means tripping said rack raising poppet valve toraise said rack to the ready position.

8. -In a device as set forth in claim 7, a foot pedal constituting saidfirst and second means; said pedal having an up ready position actuatingsaid rack raising poppet valve; and

a spring normal-1y urging said pedal in said up ready position;

said pedal having a down wrap position actuating said gate closingpoppet valve;

said pedal being depressable by an operator against said spring toactuate said gate closing poppet valve to set the automatic cycle ofsaid machine in operation;

said spring moving said pedal to the up position upon release by theoperator to actuate said rack raising poppet valve to place said rack inthe ready position.

References Cited by the Examiner UNITED STATES PATENTS 180,745 8/1876Braddock 24 518,426 4/1894 Randall 140--115 X 1,802,799 4/1931 Weston etal 140115 2,763,296 9/1956 Lecoq 1403.1 3,063,472 11/1962 Winters 1403.13,160,180 12/1964 Keeble 140-113 X WILLIAM J. STEPHENSON, PrimaryExaminer.

1. AN AUTOMATIC WIRE WRAPPING MACHINE FOR WINDING A PLURALITY OF WIRESAROUND A BASE WIRE AT THE SAME TIME COMPRISING, A PLURALITY OF WIREWRAPPING GEARS ON A COMMON ROTATIONAL AXIS, EACH SAID GEAR HAVINGOPPOSITE SIDES, A HUB PROJECTING AXIALLY ON EITHER SIDE OF EACH SAIDWIRE WRAPPING GEAR, A CIRCUMFERENTIAL EDGE, AND A RADIAL SLOT LEADINGTHROUGH SAID CIRCUMFERENTIAL EDGE AND SAID HUB TO A POINT BEYOND ANDINCLUDING THE ROTATIONAL AXIS OF SAID WIRE WRAPPING GEAR; A MACHINEFRAME, PAIRED MOUNTING PLATES ON SAID MACHINE FRAME ON EITHER SIDE OFEACH SAID WIRE WRAPPING GEAR; SAID PLATES HAVING ALIGNED BEARINGAPERTURES RECEIVING AND ROTATABLY MOUNTING EACH SAID HUB AND ABUTTINGTHE OPPOSITE SIDES OF EACH SAID WIRE WRAPPING GEAR; EACH SAID MOUNTINGPLATE HAVING A RECEIVING SLOT LEADING TO ITS SAID BEARING APERTURE ANDALIGNED PARALLEL RELATIVE TO ONE ANOTHER DEFINING A WIRE RECEIVING MOUTHIN THE MACHINE LEADING TO THE RADIAL SLOT IN EACH SAID WIRE WRAPPINGGEAR; SAID WIRE WRAPPING GEARS BEING ROTATABLE TO ALIGN THEIR RADIALSLOTS WITH THE RECEIVING SLOTS IN SAID PLATES SO THAT A BASE WIRE MOVEDRADIALLY SIDEWISE THROUGH SAID PLATE SLOTS ALSO MOVES THROUGH SAIDRADIAL SLOTS OF SAID WIRE WRAPPING GEARS SO AS TO TAKE A PROPER WORKPOSITION WITH THE AXIS OF THE BASE WIRE LYING ON THE ROTATIONAL AXIS OFSAID WIRE WRAPPING GEARS SO THAT SAID WIRE WRAPPING GEARS MAY ROTATEAROUND SAID BASE WIRE; A DRIVE GEAR ENGAGING EACH SAID WIRE WRAPPINGGEAR, A DRIVE SHAFT ROTATABLY MOUNTED ON SAID MACHINE FRAME SUPPORTINGSAID DRIVE GEARS, A DRIVE PINION GEAR ON SAID DRIVE SHAFT, A RACKRECIPROCABLY SUPPORTED ON SAID MACHINE FRAME ENGAGING SAID PINION GEAR,A RACK CYLINDER MOUNTED ON SAID MACHINE FRAME HAVING A PISTON RODCONNECTED TO SAID RACK FOR RECIPROCATING SAID RACK; MOVEMENT OF SAIDRACK ROTATING SAID PINION GEAR, DRIVE SHAFT, AND DRIVE GEARS WITH SAIDDRIVE GEARS ROTATING SAID WIRE WRAPPING GEARS; AND A RADIALLY POSITIONEDAXIALLY PROJECTING WIRE WRAPPING DOG ON EACH SAID HUB ADJACENT THERADIAL SLOT IN EACH SAID WIRE WRAPPING GEAR; SAID RACK BEING ADJUSTED INRECIPROCATING MOVEMENT SO THAT AT THE ENDS OF TRAVEL IN BOTH DIRECTIONSSAID WIRE WRAPPING GEARS ARE POSITIONED WITH THEIR RADIAL SLOTS INALIGNMENT WITH THE SLOTS IN SAID MOUNTING PLATES SO THAT THE BASE WIREMAY BE INSERTED AND EXTRACTED RELATIVE TO SAID WIRE WRAPPING GEARS; SAIDBASE WIRE BEING INSERTED AND EXTRACTED TOGETHER WITH CROSS-TIE WIRESLYING NORMAL TO THE BASE WIRE WITH THEIR ENDS PROJECTING BEYOND SAIDBASE WIRE AND PAST AND IN THE PLANE OF SAID DOGS ON SAID WIRE WRAPPINGGEARS; ROTATION OF SAID WIRE WRAPPING GEARS WITH SAID WIRES SO DISPOSEDORBITING SAID DOGS AROUND SAID BASE WIRE WITH SAID DOGS ENGAGING SAIDCROSS-TIE WIRES WHILE ORBITING, THEREBY WRAPPING THE EXTENDING ENDS OFSAID CROSS-TIE WIRES AROUND SAID BASE WIRE.